case study-kovis
TRANSCRIPT
En
erg
y se
cto
r
Instruments Remote Monitoring in Kovis Group
Input/Output Modules Use
• Published by Iskra, d.d. • Version 1.0 April 2015
Input signals of PLC
Measurement of water, heat, gas etc. consumption
Substation control accessOvervoltage protection
Measurement of solar radiation, transformer station temperature, wind speed etc.
Control Facts about Kovis Livarna
Auxiliary inputs
Use of Input /Output Modules
Power quality analyser functions also as a secondary protection device
High accurate data about consumption
Up to 32 alarmsFast notification of faults in a system
Four energy counters for four-quadrant metering
Can be viewed on device or downloaded
Alarm
Energy
About Kovis Livarna d.o.o.
Situation before the intrduction of our system
The tradition of the foundry goes back to 1968. In the 90s, we produced castings under the name of Livarna Štore. Since 1996, the foundry has been wholly owned by Anton Pangrčič and has been an independent legal entity with the name Kovis Livarna, d.o.o., since 1999. In its history, Kovis Livarna, d.o.o., has faced many challenges in the business environment.
Foundry provides castings for customers from various industries:
ź the manufacture of railway vehicles,
ź machine building,
źthe production of agricultural machinery,
źthe production of construction machinery,
źthe production of pumps, fittings and valves,
ź castings for construction ...
Because of a lack of power quality and consumption information there were big challenges to face before the introduction of our system. Kovis Livarna didn't have any information about energy consumption of different machines. It was almost impossible to determine the amount of consumed energy within the factory in relation to a particular large consumer (machine). They had difficulties composing energy consumption annual reports for regulator (IEC standardization) purposes. Supervision and determination of energy leakages from different sources like gas, water, compressed air or electricity within the factory was also very difficult. Prediction of energy consumption was complicated, because no power profile historic data was available. They had no means to centrally monitor their large energy consumers.
www.iskra.eu
Situation before the introduction of our system
WebClients
SystemServer
(local orremote)
Power qualitymeter point
Database
DataCollector
WebServer
RemoteSystem
DataMonitoring
Electrical energymeter points
Electrical parametermeter points
Electrical energymeter points
Gas/Water/Electricitymeter point
Remote Gas/Watermeter point Remote
DeviceSetting & Monitor
RemoteDevice
Setting & Monitor
DESKTOPclient
LAN SERIAL
LPR
Our Solution
ź
ź
ź
ź
ź
ź
Data aquisition & analysis
Three arch architecture
Real time alarm management
Data access administration
Power quality reports
Graphical monitoring
To be more cost effective the management of Kovis Livarna wanted to have better insight into energy consumption of the factory. For this reason we proposed an installation of Iskra electrical measuring instruments at different measuring points within the factory. Instruments were placed at strategic big energy consumption locations throughout the factory (electric furnaces, robots, cranes etc.) as well as in the central transformer station. We installed 44 low-end instruments (20 MC 330 and 24 MC 350). For communication we used the serial/Ethernet converter MI 488 device, which enables MODBUS polling of relevant data registers from the before mentioned instruments. We also collected measurements from 5 ethernet-enabled MC 750 network recorders. All measuring instruments monitor: energy, active power, reactive power, currents, voltages and phase angles. For measuring of electrical energy consumption of crucial large consumers we distributed 23 energy meters (MC 330 and WS 1302) throughout the factory. Via pulse outputs they were connected to low power radio C2 wireless devices (868 MHz) for sending data into C100 wireless communication receivers. Through C100 energy consumption data is then sent via Ethernet, into a centralized dedicated MiSmart server which is located within the company's LAN. We also equipped all measuring equipment with current transformers to do required current measurements. One of the C2 communication devices has been connected via pulse inputs (through a PLC) into an air compressor in order to measure consumption of compressed air.
Benefits MC 3x0Our solution Benefits C2 Low power Radio Counters Communicator
LPR Concentrator
Measuring Centres
Network Recorder Benefits MC 750 Benefits C100
Key user benefits
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
8 MB flash memory for recorder - MC 350
4 Energy counters Accuracy class U, I, P 0.5, active energy Class 1 (optional 0.5s)
Frequency range from 16 Hz to 400 Hz
Up to 2 tariff inputs (option)
Up to 2 pulse or relay outputs (option)
AC or Universal (option) power supply
Multilingual support (13 languages)
Isolated communication RS485 or RS232 up to 115,200 bit/s or USB 2.0 - MC 350
MODBUS communication protocol supported
User-friendly PC MiQen software
Measurements of instantaneous values of more than 60 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, etc.)
.
.
.
.
.
ź
ź
ź
ź
ź
ź
ź
ź
LPR (868 MHz) two-way communication (typically 300m range)
Low power consumption - 5 years without battery replacement Battery status display
ATEX Zone 0 certified for use in hazardous gas areas
Temperature measurement (optional)
100% reliable pulses detection
Remote/local setup
AMR for gas, water and other counters with pulse output
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
Accuracy class 0.5 (optional 0.2)
Recording up to 32 measurands and 32 alarms in the internal memory (8 MB flash) RS 232/RS 485 communication up to 115,200 bit/s or Ethernet/USB communication
MODBUS and DNP3 communication protocol
Up to 4 inputs or outputs (analogue outputs, analogue inputs, pulse outputs, alarm outputs, tariff inputs, digital inputs)
Universal or AC power supply
Adjustable tariff clock, display of electric energy consumption in optional currency
Multilingual support
User-friendly PC MiQen software
Measurements of instantaneous values of more than 1400 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, energy, energy cost by tariffs, etc.)
ź
ź
ź
ź
ź
ź
ź
C2 counters communicators control
LPR (868 Mhz) two-way communication (typically 300 m) Communication bridging (meshed type - repeater mode)
Power supply from the network
Data storage from up to 100 C2 communicators
Remote/local setup
For sending AMR data
Description of MiSmart software
MC 750 C2 C100MC 350 MC 750 C2 C100MC 350
With our system the customer now gets remote and centralized key electrical parameter data for monitoring of energy, active power, reactive power, currents, voltages, phase angles with special emphasis on electrical energy and reagent (gass, water, compressed air) consumption. Key decision makers are now able to receive real-time information on the operation of installed equipment and are also able to respond, without delay, to possible failures. They can make operational and strategic decisions based on failure analysis. The system also enables better supervision over energy losses within the factory as well as better and faster maintenance planning according to historic data. The system architecture is modular and so easily extendable to other locations and measurement points. Also a quick Excel data export capability is available for regulator reporting which enables the customer to have energy consumption reports ready after a few clicks.
Our Solution
ź
ź
ź
ź
ź
ź
Data aquisition & analysis
Three arch architecture
Real time alarm management
Data access administration
Power quality reports
Graphical monitoring
To be more cost effective the management of Kovis Livarna wanted to have better insight into energy consumption of the factory. For this reason we proposed an installation of Iskra electrical measuring instruments at different measuring points within the factory. Instruments were placed at strategic big energy consumption locations throughout the factory (electric furnaces, robots, cranes etc.) as well as in the central transformer station. We installed 44 low-end instruments (20 MC 330 and 24 MC 350). For communication we used the serial/Ethernet converter MI 488 device, which enables MODBUS polling of relevant data registers from the before mentioned instruments. We also collected measurements from 5 ethernet-enabled MC 750 network recorders. All measuring instruments monitor: energy, active power, reactive power, currents, voltages and phase angles. For measuring of electrical energy consumption of crucial large consumers we distributed 23 energy meters (MC 330 and WS 1302) throughout the factory. Via pulse outputs they were connected to low power radio C2 wireless devices (868 MHz) for sending data into C100 wireless communication receivers. Through C100 energy consumption data is then sent via Ethernet, into a centralized dedicated MiSmart server which is located within the company's LAN. We also equipped all measuring equipment with current transformers to do required current measurements. One of the C2 communication devices has been connected via pulse inputs (through a PLC) into an air compressor in order to measure consumption of compressed air.
Benefits MC 3x0Our solution Benefits C2 Low power Radio Counters Communicator
LPR Concentrator
Measuring Centres
Network Recorder Benefits MC 750 Benefits C100
Key user benefits
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
8 MB flash memory for recorder - MC 350
4 Energy counters Accuracy class U, I, P 0.5, active energy Class 1 (optional 0.5s)
Frequency range from 16 Hz to 400 Hz
Up to 2 tariff inputs (option)
Up to 2 pulse or relay outputs (option)
AC or Universal (option) power supply
Multilingual support (13 languages)
Isolated communication RS485 or RS232 up to 115,200 bit/s or USB 2.0 - MC 350
MODBUS communication protocol supported
User-friendly PC MiQen software
Measurements of instantaneous values of more than 60 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, etc.)
.
.
.
.
.
ź
ź
ź
ź
ź
ź
ź
ź
LPR (868 MHz) two-way communication (typically 300m range)
Low power consumption - 5 years without battery replacement Battery status display
ATEX Zone 0 certified for use in hazardous gas areas
Temperature measurement (optional)
100% reliable pulses detection
Remote/local setup
AMR for gas, water and other counters with pulse output
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
Accuracy class 0.5 (optional 0.2)
Recording up to 32 measurands and 32 alarms in the internal memory (8 MB flash) RS 232/RS 485 communication up to 115,200 bit/s or Ethernet/USB communication
MODBUS and DNP3 communication protocol
Up to 4 inputs or outputs (analogue outputs, analogue inputs, pulse outputs, alarm outputs, tariff inputs, digital inputs)
Universal or AC power supply
Adjustable tariff clock, display of electric energy consumption in optional currency
Multilingual support
User-friendly PC MiQen software
Measurements of instantaneous values of more than 1400 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, energy, energy cost by tariffs, etc.)
ź
ź
ź
ź
ź
ź
ź
C2 counters communicators control
LPR (868 Mhz) two-way communication (typically 300 m) Communication bridging (meshed type - repeater mode)
Power supply from the network
Data storage from up to 100 C2 communicators
Remote/local setup
For sending AMR data
Description of MiSmart software
MC 750 C2 C100MC 350 MC 750 C2 C100MC 350
With our system the customer now gets remote and centralized key electrical parameter data for monitoring of energy, active power, reactive power, currents, voltages, phase angles with special emphasis on electrical energy and reagent (gass, water, compressed air) consumption. Key decision makers are now able to receive real-time information on the operation of installed equipment and are also able to respond, without delay, to possible failures. They can make operational and strategic decisions based on failure analysis. The system also enables better supervision over energy losses within the factory as well as better and faster maintenance planning according to historic data. The system architecture is modular and so easily extendable to other locations and measurement points. Also a quick Excel data export capability is available for regulator reporting which enables the customer to have energy consumption reports ready after a few clicks.
Our Solution
ź
ź
ź
ź
ź
ź
Data aquisition & analysis
Three arch architecture
Real time alarm management
Data access administration
Power quality reports
Graphical monitoring
To be more cost effective the management of Kovis Livarna wanted to have better insight into energy consumption of the factory. For this reason we proposed an installation of Iskra electrical measuring instruments at different measuring points within the factory. Instruments were placed at strategic big energy consumption locations throughout the factory (electric furnaces, robots, cranes etc.) as well as in the central transformer station. We installed 44 low-end instruments (20 MC 330 and 24 MC 350). For communication we used the serial/Ethernet converter MI 488 device, which enables MODBUS polling of relevant data registers from the before mentioned instruments. We also collected measurements from 5 ethernet-enabled MC 750 network recorders. All measuring instruments monitor: energy, active power, reactive power, currents, voltages and phase angles. For measuring of electrical energy consumption of crucial large consumers we distributed 23 energy meters (MC 330 and WS 1302) throughout the factory. Via pulse outputs they were connected to low power radio C2 wireless devices (868 MHz) for sending data into C100 wireless communication receivers. Through C100 energy consumption data is then sent via Ethernet, into a centralized dedicated MiSmart server which is located within the company's LAN. We also equipped all measuring equipment with current transformers to do required current measurements. One of the C2 communication devices has been connected via pulse inputs (through a PLC) into an air compressor in order to measure consumption of compressed air.
Benefits MC 3x0Our solution Benefits C2 Low power Radio Counters Communicator
LPR Concentrator
Measuring Centres
Network Recorder Benefits MC 750 Benefits C100
Key user benefits
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
8 MB flash memory for recorder - MC 350
4 Energy counters Accuracy class U, I, P 0.5, active energy Class 1 (optional 0.5s)
Frequency range from 16 Hz to 400 Hz
Up to 2 tariff inputs (option)
Up to 2 pulse or relay outputs (option)
AC or Universal (option) power supply
Multilingual support (13 languages)
Isolated communication RS485 or RS232 up to 115,200 bit/s or USB 2.0 - MC 350
MODBUS communication protocol supported
User-friendly PC MiQen software
Measurements of instantaneous values of more than 60 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, etc.)
.
.
.
.
.
ź
ź
ź
ź
ź
ź
ź
ź
LPR (868 MHz) two-way communication (typically 300m range)
Low power consumption - 5 years without battery replacement Battery status display
ATEX Zone 0 certified for use in hazardous gas areas
Temperature measurement (optional)
100% reliable pulses detection
Remote/local setup
AMR for gas, water and other counters with pulse output
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
Accuracy class 0.5 (optional 0.2)
Recording up to 32 measurands and 32 alarms in the internal memory (8 MB flash) RS 232/RS 485 communication up to 115,200 bit/s or Ethernet/USB communication
MODBUS and DNP3 communication protocol
Up to 4 inputs or outputs (analogue outputs, analogue inputs, pulse outputs, alarm outputs, tariff inputs, digital inputs)
Universal or AC power supply
Adjustable tariff clock, display of electric energy consumption in optional currency
Multilingual support
User-friendly PC MiQen software
Measurements of instantaneous values of more than 1400 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, energy, energy cost by tariffs, etc.)
ź
ź
ź
ź
ź
ź
ź
C2 counters communicators control
LPR (868 Mhz) two-way communication (typically 300 m) Communication bridging (meshed type - repeater mode)
Power supply from the network
Data storage from up to 100 C2 communicators
Remote/local setup
For sending AMR data
Description of MiSmart software
MC 750 C2 C100MC 350 MC 750 C2 C100MC 350
With our system the customer now gets remote and centralized key electrical parameter data for monitoring of energy, active power, reactive power, currents, voltages, phase angles with special emphasis on electrical energy and reagent (gass, water, compressed air) consumption. Key decision makers are now able to receive real-time information on the operation of installed equipment and are also able to respond, without delay, to possible failures. They can make operational and strategic decisions based on failure analysis. The system also enables better supervision over energy losses within the factory as well as better and faster maintenance planning according to historic data. The system architecture is modular and so easily extendable to other locations and measurement points. Also a quick Excel data export capability is available for regulator reporting which enables the customer to have energy consumption reports ready after a few clicks.
Our Solution
ź
ź
ź
ź
ź
ź
Data aquisition & analysis
Three arch architecture
Real time alarm management
Data access administration
Power quality reports
Graphical monitoring
To be more cost effective the management of Kovis Livarna wanted to have better insight into energy consumption of the factory. For this reason we proposed an installation of Iskra electrical measuring instruments at different measuring points within the factory. Instruments were placed at strategic big energy consumption locations throughout the factory (electric furnaces, robots, cranes etc.) as well as in the central transformer station. We installed 44 low-end instruments (20 MC 330 and 24 MC 350). For communication we used the serial/Ethernet converter MI 488 device, which enables MODBUS polling of relevant data registers from the before mentioned instruments. We also collected measurements from 5 ethernet-enabled MC 750 network recorders. All measuring instruments monitor: energy, active power, reactive power, currents, voltages and phase angles. For measuring of electrical energy consumption of crucial large consumers we distributed 23 energy meters (MC 330 and WS 1302) throughout the factory. Via pulse outputs they were connected to low power radio C2 wireless devices (868 MHz) for sending data into C100 wireless communication receivers. Through C100 energy consumption data is then sent via Ethernet, into a centralized dedicated MiSmart server which is located within the company's LAN. We also equipped all measuring equipment with current transformers to do required current measurements. One of the C2 communication devices has been connected via pulse inputs (through a PLC) into an air compressor in order to measure consumption of compressed air.
Benefits MC 3x0Our solution Benefits C2 Low power Radio Counters Communicator
LPR Concentrator
Measuring Centres
Network Recorder Benefits MC 750 Benefits C100
Key user benefits
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
8 MB flash memory for recorder - MC 350
4 Energy counters Accuracy class U, I, P 0.5, active energy Class 1 (optional 0.5s)
Frequency range from 16 Hz to 400 Hz
Up to 2 tariff inputs (option)
Up to 2 pulse or relay outputs (option)
AC or Universal (option) power supply
Multilingual support (13 languages)
Isolated communication RS485 or RS232 up to 115,200 bit/s or USB 2.0 - MC 350
MODBUS communication protocol supported
User-friendly PC MiQen software
Measurements of instantaneous values of more than 60 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, etc.)
.
.
.
.
.
ź
ź
ź
ź
ź
ź
ź
ź
LPR (868 MHz) two-way communication (typically 300m range)
Low power consumption - 5 years without battery replacement Battery status display
ATEX Zone 0 certified for use in hazardous gas areas
Temperature measurement (optional)
100% reliable pulses detection
Remote/local setup
AMR for gas, water and other counters with pulse output
ź
ź
ź
ź
ź
ź
ź
ź
ź
ź
Accuracy class 0.5 (optional 0.2)
Recording up to 32 measurands and 32 alarms in the internal memory (8 MB flash) RS 232/RS 485 communication up to 115,200 bit/s or Ethernet/USB communication
MODBUS and DNP3 communication protocol
Up to 4 inputs or outputs (analogue outputs, analogue inputs, pulse outputs, alarm outputs, tariff inputs, digital inputs)
Universal or AC power supply
Adjustable tariff clock, display of electric energy consumption in optional currency
Multilingual support
User-friendly PC MiQen software
Measurements of instantaneous values of more than 1400 quantities (U, I, P, Q, S, PF, PA, f, ϕ, THD, MD, energy, energy cost by tariffs, etc.)
ź
ź
ź
ź
ź
ź
ź
C2 counters communicators control
LPR (868 Mhz) two-way communication (typically 300 m) Communication bridging (meshed type - repeater mode)
Power supply from the network
Data storage from up to 100 C2 communicators
Remote/local setup
For sending AMR data
Description of MiSmart software
MC 750 C2 C100MC 350 MC 750 C2 C100MC 350
With our system the customer now gets remote and centralized key electrical parameter data for monitoring of energy, active power, reactive power, currents, voltages, phase angles with special emphasis on electrical energy and reagent (gass, water, compressed air) consumption. Key decision makers are now able to receive real-time information on the operation of installed equipment and are also able to respond, without delay, to possible failures. They can make operational and strategic decisions based on failure analysis. The system also enables better supervision over energy losses within the factory as well as better and faster maintenance planning according to historic data. The system architecture is modular and so easily extendable to other locations and measurement points. Also a quick Excel data export capability is available for regulator reporting which enables the customer to have energy consumption reports ready after a few clicks.
En
erg
y se
cto
r
Instruments Remote Monitoring in Kovis Group
Input/Output Modules Use
• Published by Iskra, d.d. • Version 1.0 April 2015
Input signals of PLC
Measurement of water, heat, gas etc. consumption
Substation control accessOvervoltage protection
Measurement of solar radiation, transformer station temperature, wind speed etc.
Control Facts about Kovis Livarna
Auxiliary inputs
Use of Input /Output Modules
Power quality analyser functions also as a secondary protection device
High accurate data about consumption
Up to 32 alarmsFast notification of faults in a system
Four energy counters for four-quadrant metering
Can be viewed on device or downloaded
Alarm
Energy
About Kovis Livarna d.o.o.
Situation before the intrduction of our system
The tradition of the foundry goes back to 1968. In the 90s, we produced castings under the name of Livarna Štore. Since 1996, the foundry has been wholly owned by Anton Pangrčič and has been an independent legal entity with the name Kovis Livarna, d.o.o., since 1999. In its history, Kovis Livarna, d.o.o., has faced many challenges in the business environment.
Foundry provides castings for customers from various industries:
ź the manufacture of railway vehicles,
ź machine building,
źthe production of agricultural machinery,
źthe production of construction machinery,
źthe production of pumps, fittings and valves,
ź castings for construction ...
Because of a lack of power quality and consumption information there were big challenges to face before the introduction of our system. Kovis Livarna didn't have any information about energy consumption of different machines. It was almost impossible to determine the amount of consumed energy within the factory in relation to a particular large consumer (machine). They had difficulties composing energy consumption annual reports for regulator (IEC standardization) purposes. Supervision and determination of energy leakages from different sources like gas, water, compressed air or electricity within the factory was also very difficult. Prediction of energy consumption was complicated, because no power profile historic data was available. They had no means to centrally monitor their large energy consumers.
www.iskra.eu
Situation before the introduction of our system
WebClients
SystemServer
(local orremote)
Power qualitymeter point
Database
DataCollector
WebServer
RemoteSystem
DataMonitoring
Electrical energymeter points
Electrical parametermeter points
Electrical energymeter points
Gas/Water/Electricitymeter point
Remote Gas/Watermeter point Remote
DeviceSetting & Monitor
RemoteDevice
Setting & Monitor
DESKTOPclient
LAN SERIAL
LPR
En
erg
y se
cto
r
Instruments Remote Monitoring in Kovis Group
Input/Output Modules Use
• Published by Iskra, d.d. • Version 1.0 April 2015
Input signals of PLC
Measurement of water, heat, gas etc. consumption
Substation control accessOvervoltage protection
Measurement of solar radiation, transformer station temperature, wind speed etc.
Control Facts about Kovis Livarna
Auxiliary inputs
Use of Input /Output Modules
Power quality analyser functions also as a secondary protection device
High accurate data about consumption
Up to 32 alarmsFast notification of faults in a system
Four energy counters for four-quadrant metering
Can be viewed on device or downloaded
Alarm
Energy
About Kovis Livarna d.o.o.
Situation before the intrduction of our system
The tradition of the foundry goes back to 1968. In the 90s, we produced castings under the name of Livarna Štore. Since 1996, the foundry has been wholly owned by Anton Pangrčič and has been an independent legal entity with the name Kovis Livarna, d.o.o., since 1999. In its history, Kovis Livarna, d.o.o., has faced many challenges in the business environment.
Foundry provides castings for customers from various industries:
ź the manufacture of railway vehicles,
ź machine building,
źthe production of agricultural machinery,
źthe production of construction machinery,
źthe production of pumps, fittings and valves,
ź castings for construction ...
Because of a lack of power quality and consumption information there were big challenges to face before the introduction of our system. Kovis Livarna didn't have any information about energy consumption of different machines. It was almost impossible to determine the amount of consumed energy within the factory in relation to a particular large consumer (machine). They had difficulties composing energy consumption annual reports for regulator (IEC standardization) purposes. Supervision and determination of energy leakages from different sources like gas, water, compressed air or electricity within the factory was also very difficult. Prediction of energy consumption was complicated, because no power profile historic data was available. They had no means to centrally monitor their large energy consumers.
www.iskra.eu
Situation before the introduction of our system
WebClients
SystemServer
(local orremote)
Power qualitymeter point
Database
DataCollector
WebServer
RemoteSystem
DataMonitoring
Electrical energymeter points
Electrical parametermeter points
Electrical energymeter points
Gas/Water/Electricitymeter point
Remote Gas/Watermeter point Remote
DeviceSetting & Monitor
RemoteDevice
Setting & Monitor
DESKTOPclient
LAN SERIAL
LPR